Modular building system

ABSTRACT

A building system for the construction of low cost versatile single and multilevel residential and commercial structures using unique modular components and a unique way these components are geometrically integrated together. Basically this system relies upon the use of a central support column from which floors and ceilings are cantilevered outwardly. The central support module (one per floor) is hexagon shaped and contains built in stairs, utility stacks, entrance areas and elevator space. This central support module supports the special beams which are attached to the sides of the module near the top to form cantilevered floors. Depending upon whether the structure is to be single or multileveled, these support modules may be stacked atop one another to whatever height is desired, with one module and one set of beams being required for each floor. The special beams required are in reality two beams overlapped and fastened together at one end so as to have one high portion and one low portion. This feature allows the beams to interweave together around the hexagon shaped support module. Supplemental beams are then added to integrate and strengthen the cantilevered areas. Because of the geometric design and integration of these beams, standard triangle shaped floor and ceiling sections may be added for complete area coverage. The structures may be then left open, or enclosed with modular curtain walls with any desired interior rooms arranged likewise.

United States Patent 1 Rader [451 Sept. 4, 1973 MODULAR BUILDING SYSTEM T. Freeman Rader, 447 S. Grant St., Denver, Colo. 80209 [22] Filed: Sept. 14, 1971 [21] Appl. No.: 180,402

[76] Inventor:

Primary Examiner-Frank L. Abbott Assistant Examiner-Henry E. Raduazo Att0rneyRichard D. Law

I 7] ABSTRACT A building system for the construction-of low cost versatile single and multilevel residential and commercial structures using unique modular components and a unique way these components are geometrically integrated together. Basically,this system relies upon the use of a central support column from which floors and ceilings are cantilevered outwardly. The central support module (one per floor) is hexagon shaped and contains built in stairs, utility stacks, entrance areas and elevator space. This central support module supports the special beams which are attached to the sides of the module near the top to form cantilevered floors. Depending upon whether the structure is to be single or multileveled, these support modules may be stacked atop one another to whatever height is desired, with one module and one set of beams being required for each floor. The special beams required are in reality two beams overlapped and fastened together at one end so as to have one high portion and one low portion. This feature allows the beams to interweave together around the hexagon shaped support module. Supplemental beams are then added to integrate and strengthen the cantilevered areas. Because of the geometric design and integration of these beams, standard triangle shaped floor and ceiling sections may be added for complete area coverage. The structures may be then left open, or enclosed with modular curtain walls with any desired interior rooms arranged likewise.

4 Claims, 20 Drawing Figures PATENTEDSEP 4 I13 SHEET 3 0F 3 FIG. I?

FIG. I8

FIG. 20

FIG. l9

MODULAR BUILDING SYSTEM Traditional buildings, both residential and commercial, tend to use box-like construction, and as a result have boxlike partitions and appearance. Modern materials and technology now give rise to the development of new principals of construction which can free builders and inhabitants alike from these conventional structural and aesthetic limitations. The present invention is one such development. It presents a unique principle of construction from which a variety of unusual single and multilevel structures can be built.

Among the objects and advantages of the present invention is to provide a complete modular system for building structures.

Another object of the invention is to provide a modular building system for constructing single or multiple level units with similar components.

Another object of the invention is to provide a modular component system wherein a single central support module supports cantilevered floor arrangements for both single and multilevel structures.

A further object of the invention is to provide an economical building system which is simple to produce and erect.

A still further object of the invention is to provide a fast and economical method of constructing buildings from modular components.

Yet another object of the invention is to provide a modular building system using a minimum of components, all of which are factory producable.

Another object of the invention is to provide a building system of reduced construction costs, reduced construction time but with maximum flexibility of floor space and room arrangement.

Another object of the invention is to provide large covered areas through the use of cantilevering techniques, thereby eliminating exterior building supports and providing maximum showroom" type exposure.

Another object of the invention is to provide a building system having greater structural strength in cantilevered floors by means of a geometrical integration of structural components.

Another object of the invention is to provide a building system which occupies minimum ground area and minimum obstructions to natural ground environment.

Another object of the invention is to provide a building system of light weight materials but which is less susceptable to earthquake damage, as the foundation is not spread over a large area.

These and other objects and advantages of the invention may be readily ascertained by referring to the following description and appended illustrations in which: FIG. I is a schematic perspective view of a hexagonal, center support module of the building FIGS. 2-8 are schematic views of components of a building system according to the invention including: FIG. 2 showing a special off-set beam, FIG. 3 a shorter interconnecting beam, FIG. 4 a spacer beam, FIG. 5 a face plate, FIG. 6 a triangular floor or ceiling section, FIG. 7 a solid wall section and FIG. 8 a glass wall section, all in general proportion to each other; (such numerals used in FIG. 1-8 are duplicated in FIG. 9-12 because they make cross reference to the same components);

FIGS. 9-12 are schematic top plan views of the method of construction, illustrating various steps, in-

cluding in FIG. 9 the central support module, FIG. 10 the module with the stepped beamsof FIG. 2 mounted thereon, FIG. 11 having the supplemental interconnecting beams mounted in position, and FIG. 12 having triangular floor sections mounted thereon;

FIG. 13 is a perspective view of the central support module with stairs, utility stacks and elevator space;

FIG. 14 is a perspective view of one of the special offset beams which is used to provide the main support for the cantilevered floors;

FIG. 15 is a perspective detail of the cantilevered, integrated beam system mounted on a central support module;

FIG. 16 is a perspective view of the floor structure with modular floor sections mounted on the cantilevered beam system, and showing an elevated central floor area (in place) and an additional elevated floor area which can be placed atop the regular floor;

FIG. 17 is a schematic side elevation of a roofed, open structure formed of the components of the building system of the invention;

FIG. 18 is a schematic side elevation of an elevated single floor structure according to the invention;

FIG. 19 is a schematic side elevation of a ground level, single floor building according to the present invention; and

FIG. 20 is a schematic side elevation of a multiple level structure according to the invention.

In a preferred form, the modular system includes a stackable, central hexagonal support module which provides the entrance to the individual levels, stairs, elevator service, and utility service stacks as required. In one convenient form, the dimensions of the support module are 11 feet high, 12 feet wide (side to side) or 13 feet 6 inches (column to column). Cantilevered floors may be secured to the central module near its top for lightness and strength. A set of six special offset support beams are secured to the central support module with both ends of the beams cantilevered from the module to provide means for attaching supplemental beams, flooring and other elements such as curtain walls and partitions for the individual floors. Any number of central support modules may be placed one on top of the other, and with the beams secured to each module a series of tiers or floors are formed upwardly from the base central support module. Using 51-foot support beams a 12 sided polygon cantilevered floor is produced. Using a central hexagon structure, a floor support beam is secured along each side of the hexagon near the top. With other shapes of structures, a floor support beam along the face of each side of the polygon will produce a different shaped peripheral structure. The following description is directed to a central hexagon structure, with the six floor support beams secured thereto, however, it is intended that other shapes are included in the general concept.

A central support module, shown in general by FIG. 13 includes an upper hexagonal support base 12a (formed of a series of beams) and a corresponding lower hexagonal support base 12b (formed of similar beams to the section 12a) spaced apart by means of alike vertical beams 15a, 15b, etc, which are secured between the hexagonal support bases at each corner. The hexogonal central support module is hollow, providing space for stairs 16, an additional space for an elevator l7, utility service stacks l8, and the like, extending from the bottom through the top thereof. A set of six cantilevered support beams are secured to the hexagonal central support module near the top, with one beam attached to each of the six sides. FIG. 14 illustrates the type of special support beam required. Since the set of six beams will intersect each other, when secured alongside the support module, it is necessary to have a high portion and a low portion to each beam, in order that the high portion of one beam may cross over the low portion of another.

Consequently, each cantilever beam is formed as two-part, shown in FIG. 14, wherein a low beam portion 20a is secured to a high beam portion 20b to form complete beam 20. The higher beam 20b overlaps and is secured by one end atop the opposite end of beam 20a. The beams may be formed inmanufacturing or may be secured together by bolting, welding, or the like, to provide a rigid structuralelement. The beams may be I-beams, channels, or the like, and made of lightweight alloys to provide light, high strength structural elements. The beams may be pre-manufactured or they may be bolted together or welded together on the site. Additionally, the central support module may be pre-assembled or may be assembled on the site ready for the attachment of the cantilevered beams. To support the beams on the central support structure channels, angles or the like may be secured across the vertical uprights of the central support section for supporting the cantilevered beams.

As illustrated in FIG. 15, the off-set support beams intersect and cross over each other to illustrate the relation of the beams in the interlacing position. In the case, the low portion 20a of beam 20 is crossed over by support beams 21' and 22. The high portion 20b of beam 20, in turn, crosses over support beams 23 and 24. Each major support beam crosses and directly connects with four out of the other five support beams. When the additional supplemental interconnecting beams 26, 27, 28, etc. are added, then all beams are directly or indirectly connected with all other beams, thus providing a total integration of the structural beam network. The section 20b of beam 20'is on the same horizontal plane as the upper sections of the other beams while the lower section is on the same horizontal plane as the lower sections of the other beams. To equalize the height of the top of the lower sections of the beams spacer elements secured to the lower sections provide a level top. For example, spacers 33a and 33b are mounted on beam section 20a to provide a top level with section 201;. In a similar manner spacers are provided in such spaces between the crossed beams as may be desired. Since each beam crosses four support beams, a series of such spacers are necessary to provide a level support for flooring sections. The spacer bars may be bolted, welded, or otherwise secured to the various beam members and when properly secured add strength to the flooring of the individual tiers.

With a central support column of l l-foot height and 12-foot from side to side and l3-feet 6-inches from corner to corner, SI-feet long high-low beams secured thereto provide a l2-sided cantilevered tier. Six of the supplemental interconnecting beams 26, 27, 28, etc., are used, and these are 24-feet in length. Such beams, likewise, are made of the lightweight alloy. Twelve spacer beams, resting atop low beam portions, are then added to complete the beam network and provide a level base upon which floor sections can then be added. The interlaced beams may be covered with a decking material formed of lightweight structural panels, for example, made out of laminated structural foam or comparable material. By providing standardized triangular panels of 12 8 X 7 4 X 14 feet 8 inches, approximately 4-inches thick, a floor is readily formed as shown in FIG. 16, by placing the modular floor sections 8a, 8b, 8c, 8d, etc. adjacent and edgewise to each other on the underlying beam network. A total of 42 of these standard modular floor sections will cover the entire tier. Face plates 7 of appropriate dimensions are then added to the peripheral edge of the tier to complete it. These face plates extend slightly above and below the thickness of each tier in order to provide a surface to which the modular exterior wall curtain panels may be attached.

As shown in FIG. 16, a completed tier is mounted on a central module 10. A central elevated portion 47 (formed of the same modular floor sections) may be provided surrounding the central module 10 which permits this entrance and ball area to feature a stepdown or sunken living room effect to other areas. An additional functional advantage is that the utility lines extending from the central building column may be easily directed and routed underneath such raised portions to any area on the tier and have such utilities cov ered. The elevated entrance area may be readily assembled by using six of the standard flooring sections (previously described) placed atop respective frames to provide the necessary elevation. Similarly, other elevated floor areas 8x can be created anywhere on the tier by placing elevated floor sections together. Such a raised area may be especially desirable for the kitchen or bathroom areas as they would provide space underneath for drain pipes and also provide for interesting design features such as sunken bathtubs.

Having completed the beam structure of the tier on the central support structure 10, an additional floor may now be placed on the unit. This is accomplished by assembling another central support module and placing it on top of the bottom support module and securing it in place. The module may, also, be formed in place on top of the lower module, or it may be formed as a complete unit and placed on the lower unit by means of a crane or the like. Once the next central module is placed on the lower central module, the cantilevered beams are then secured to the second module, duplicating the construction steps previously described. Once all the beams are placed on the second module, flooring may then be added to the second tier, and after the face plates have been added, the first deck may be enclosed and interior construction completed. If additional floors are needed the construction is continued in a similar manner, providing a central support module on top of the support module already in place and the cantilever beams being subsequently added as described. One variation of the construction steps involved would be to stack up all central support modules together first and then add the beams afterwards. The underneath part of each tier may be finished in a smooth, suspended, grid ceiling, (not shown) using similar sections to the floor sections, although lighter and thinner, and suspended from the beams. Such a construction, of course, permits accessibility to overhead electrical conduits, lighting system, sprinkler systems, and the like. The walls of the central support module, open to the tier, are then enclosed. For access into the central module from a tier, doors or the like are provided into the central support module. With elevators, stairs and service stacks included, a hallway is, also, included in each of the central support modules permitting egress and ingress to and from each level. In some instances it may be desirable to close in the bottom of the first tier (forming a ground floor) to provide additional housing units, or in other cases it may be desirable to leave this area open which provides parking or the like as desired by the owner.

Once the individual tiers are completed and floored as shown, the owners may finish the interior of each tier in any manner desired by the individuals. Modular wall panels used for both interior and exterior completion are 2 foot wide and extend from floor to ceiling. They are made out of either solid material or plain galss or stained glass, and are interchangeable. They are so designed to provide adequate thermal and sound insulation.

The versatility of the construction is illustrated in FIGS. 17 through 20. In FIG. 17 a simple covered building is illustrated, wherein a central support module 50 is covered by a tier 51 having a top completely enclosed and weatherproofed. In this case, the central support module is likewise enclosed and the module itself may be used for interior space. The overhang of the cantilevered tier provides parking for vehicles, drive in facilities, and shelter for patrons that may utilize the building. As shown in FIG. 18, an elevated one-story structure is provided by utilizing two central support modules 52a and 52b and two tiers 53a and 53b. A curtain wall 54, indicated in dashed lines for clarity, extends around the building between the upper and lower tiers enclosing the area therebetween, with parking and patio space under the building. The interior space in the central support modules of single story structure do not require elevator space or utility stacks etc, and can be modified accordingly. The roof area is, of course, weatherproofed and may be used as a sundeck.

A slightly different type of one-story building is shown in FIG. 19, wherein a single lower central module 55 supports a tier 56. A curtain wall 59 (shown in dashed lines) completes the enclosure forming a ground level one-story unit. This unit may be formed on a concrete pad or the like.

As illustrated in FIG. 20 a multiple-story building is formed on a lower central support module 60 with a series of tiers of floors thereabove 61a, 61b, 16c, etc. Each tier, of course, includes a central support module mounted one above the other in the unit, and in this case an upper central support module 62 provides housing for various utilities which may be necessary for the building. Such utillties may be elevator motors, controls, and the like, air conditioning units, and other similar utilities. The top deck 63 may be used as a recreational area for the occupants of the building, forming an open-air deck area. The number of floors are determined by the designer or the owners of the building. A curtain, outer wall 64 encloses the tiers, forming the enclosed floors. Parking or recreation space, shown in general by numeral 70, is provided under the building at ground level.

The versatility of the building system is readily seen from FIGS. 17 through 20. It is also obvious that the size of the individual components determines the finished size of the resultantbuilding. Thus, for a high-rise apartment building, for example, larger and stronger beams might be necessary over those used in the simple shelter structure of FIG. 16. Furthermore, on increasing the length of the overhang of the cantilevered tiers, additional strength must be provided to support the cantilevered floor members. One very economical aspect of the construction is the use of similar construction elements for each of the floors of a building of any height. Further, since each tier supports only the load on that tier, all the tier structural elements may be made the same. The central support module may be varied in strength if desired from the bottom to the top, depending on the architectural and engineering considerations.

I claim:

1. Building system comprising a. a hexagonal single story central support module, for supporting cantilevered floor/ceilings, which contains built-in stairs, utility stacks, elevator space, and entrance areas;

b. a plurality of major cantilevered beams which attach tangentially to the faces of the sides of the support module near its top, and extend outwardly therefrom in both directions to cross and integrate with each other to fomi the basic structuralsupport for the cantilevered floor/ceilings; I

. a plurality of supplemental beams which interconnect the major support beams to provide lateral structural integrity, strength, and support for the cantilevered floor/ceilings;

d. a plurality of spacer beams which rest atop the low portions of the major support beams to establish a level overall beam upper surface for support of the cantilevered floor/ceilings; and

e. a plurality of similar floor/ceiling sections which overlay the cantilevered beam structural grid to provide area coverage and completion 'of the cantilevered floor/ceilings.

2. Building system according to claim 1 whereby said major cantilever beams are special offset support beams, each consisting of one high portion and one low portion, intersect, cross over, and integrate with each other in a designated geometric pattern.

3. Building system according to claim 1 whereby the structural components assemble together in a geometrically integrated pattern thus producing a beam network of great structural strength, and a support grid upon which an overlay of alike triangular floor/ceiling sections may be geometrically placedfor complete area coverage of the cantilevered floor/ceilings.

4. Building system according to claim 1 which enables components to be assembled to form single level structures, either left open or enclosed by curtain walls, or stacked atop each other in a sequence of support modules and cantilevered floors to form multi-level structures.

is s m s c UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No- 3755973 Dated September 4, 1973 lnventofls) T. Freeman Rader It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Col. 4; line 4, should read panels of 12 feet 8 inches x 7 feet 4 inches x 1.4 feet 8 inches, approximately Signed and sealed this Lpch day or June 19m.

(SEAL) Attest:

EDWARD M.FLE'1TCHER,JR.

c. MARSHALL DANN Attestingg Officer 7 Corrmnissioner' of "Batents ORM P0 1050 (10-69) USCOMM-DC 60376-8 69 1 u. s. aovnuurm' nnmm: ornca l9! 0-386-334 

1. Building system comprising a. a hexagonal single story central support module, for supporting cantilevered floor/ceilings, which contains built-in stairs, utility stacks, elevator space, and entrance areas; b. a plurality of major cantilevered beams which attach tangentially to the faces of the sides of the support module near its top, and extend outwardly therefrom in both directions to cross and integrate with each other to form the basic structural support for the cantilevered floor/ceilings; c. a plurality of supplemental beams which interconnect the major support beams to provide lateral structural integrity, strength, and support for the cantilevered floor/ceilings; d. a plurality of spacer beams which rest atop the low portions of the major support beams to establish a level overall beam upper surface for support of the cantilevered floor/ceilings; and e. a plurality of similar floor/ceiling sections which overlay the cantilevered beam structural grid to provide area coverage and completion of the cantilevered floor/ceilings.
 2. Building system according to claim 1 whereby said major cantilever beams are special offset support beams, each consisting of one high portion and one low portion, intersect, cross over, and integrate with each other in a designated geometric pattern.
 3. Building system according to claim 1 whereby the structural components assemble together in a geometrically integrated pattern thus producing a beam network of great structural strength, and a support grid upon which an overlay of alike triangular floor/ceiling sections may be geometrically placed for complete area coverage of the cantilevered floor/ceilings.
 4. Building system according to claim 1 which enables components to be assembled to form single level structures, either left open or enclosed by curtain walls, or stacked atop each other in a sequence of support modules and cantilevered floors to form multi-level structures. 